CHAPTER-2

LATHE
 LATHE
ITRODUCTION
 Lathes were developed as early as the 15th century.
 Lathe is one of the most versatile and widely used machine tools all
over the world. It is commonly known as the mother of all other
machine tool.
 Lathes have allowed man to reshape, machine and manufacture
many precision cylindrical components made of various types of
metal, wood, plastics, and other materials.
 The main function of a lathe is to remove metal from a job to give it
the required shape and size.
 Working principle of lathe M/C

 The job is securely and rigidly held in the chuck or in between

centers on the lathe machine and then turn it against a single
point cutting tool which will remove metal from the job in the
form of chips. The cutting tool is rigidly held and supported in a
tool post and is fed against the revolving work.
 An engine lathe is the most basic and simplest form of the lathe.
 TYPES OF LATHE:

 Lathes are manufactured in a variety of types and sizes, from very small bench lathes
used for precision work to huge lathes used for turning large steel shafts. But the
principle of operation and function of all types of lathes is same. The different types of
lathes are:

1. Speed lathe

a) Wood working

b) Spinning

c) Centering

d) Polishing

2. Centre or engine lathe

a) Belt drive

b) Individual motor drive

c) Gear head lathe

3. Bench lathe

4. Tool room Lathe

5. Capstan and Turret lathe

6. Special purpose lathe

a) Whee1 lathe

b) Gap bed lathe

c) Duplicating lathe

d) T-lathe

7. Automatic lathe
 SPEED LATHE
 Speed lathe is simplest of all types of lathes in construction and
operation.
 The “Speed lathe” has been so named because of the very high speed
of the headstock spindle.
 It has Bed, Headstock, Tailstock, and Tool post mounted on an
adjustable slide.
 It has no feed box, lead screw or conventional type of carriage.
 The speed lathe finds applications where cutting force is least such as
in wood working, spinning, centering, polishing, winding, etc.
 High spindle speed which usually range from 1200 to 3600 r.p.m.
 Engine Lathe or Centre Lathe :

 The term “engine” is associated with this lathe due to the fact
that in the very early days of its development it was driven by
steam engine.
 It’s headstock is much more robust in construction and
contains additional mechanism for driving the lathe spindle at
multiple speeds.
 The power may be transmitted by means of belt, electric
motor or through gears.
 Bench Lathe:

 This is a small lathe usually mounted on a bench.

 It has practically all the parts of an engine lathe or speed lathe
and it performs almost all the operations.
 This is used for small and precision work.
 Tool Room Lathe:

 This lathe has features similar to an engine lathe but it is much

more accurately built.

 It has a wide range of spindle speeds ranging from a very low to a

quite high speed up to 2500 rpm.

 This lathe is mainly used for precision work on tools, dies, gauges

and in machining work where accuracy is needed.

 Capstan and Turret Lathe :

 The development of these Lathes results from the technological

advancement of the engine lathe and these are vastly used for
mass production work.
 Tailstock of an engine lathe is replaced by a hexagonal turret, on
the face of which multiple tools may be fitted .
 Several different types of operations can be done on a job
without re-setting of work or tools,
 Special Purpose Lathes:

 These lathes are constructed for special purposes and for jobs,
which cannot be accommodated or conveniently machined on a
standard lathe.
 The wheel lathe is made for finishing the journals and
locomotive wheels.
 Automatic Lathes:

 These lathes are so designed that all the working and job
handling movements of the complete manufacturing process
for a job are done automatically.
 These are high speed, heavy duty, mass production lathes
with complete automatic control.
 CONSTRUCTION OF LATHE MACHINE:

 A simple lathe comprises of a bed made of grey cast iron on which headstock,
tailstock, carriage and other components of lathe are mounted. Fig. shows the
different parts of engine lathe or central lathe. The major parts of lathe machine
are given as under:
 Bed

 Head stock

 Tailstock

 Carriage

 Feed mechanism

 Thread cutting mechanism

 Bed:

 The bed of a lathe machine is the base on which all other parts of

lathe are mounted.

 On left end of the bed, headstock of lathe machine is located

while on right side tailstock is located.

 The carriage of the machine rests over the bed and slides on it.

 On the top of the bed there are two sets of guideways- innerways

and outerways.
 Head Stock:

 The main function of headstock is to transmit power to the

different parts of a lathe.

 It comprises of the headstock casting to accommodate all the

parts within it including gear train arrangement.

 The main spindle is adjusted in it, which possesses live centre to

which the work can be attached.

 Some gears called change wheels are used to produce different

velocity ratio required for thread cutting.
 Tail Stock:

 It is commonly used for the objective of primarily giving a support the to

the circular job being turned on centers.

 It carries a centre called dead centre for supporting one end of the work.

 Both live and dead centers have 60° conical points to fit centre holes in

the circular job.

 The dead centre can be mounted in ball bearing so that it rotates with

the job avoiding friction of the job with dead centre as it important to

hold heavy jobs.

 Carriage:

 Carriage is mounted on the outer guide ways of lathe bed and it can move in a
direction parallel to the spindle axis.

 It comprises of important parts such as apron, cross-slide, saddle, compound

rest, and tool post.

 Apron: It contain gears ,clutches & levers for operating the carriage by
hand & power feeds. It uses friction clutches for automatic feed.

 Cross-slide : The cross-slide is basically mounted on the carriage, which

generally travels at right angles to the spindle axis.

 Saddle: A saddle is mounted on the cross-slide, in which the compound

rest is adjusted which can rotate and Fix to any desired angle.
 Compound rest: The compound rest or compound slide is mounted on
the top of the cross slide and has a circular base graduated in degrees. It
is used for providing angular cuts and short taper as well as convenient
position of the tool to the work.

 Tool post: The tool post is an important part of carriage & is located on
the top of the compound rest to hold the tool and to enable it to be
adjusted to a convenient working position.
 Feed Mechanism:
 Feed mechanism is the combination of different units through which motion of headstock
spindle is transmitted to the carriage of lathe machine.

 Following units play role in feed mechanism of a lathe machine-

 End of bed gearing: Transmits the rotary motion of headstock spindle to the feed gear
box.

 Feed gear box: Fitted below headstock assembly & it change the rate of feed

 Lead screw and feed rod: Lead screw is long threaded shaft which is used into
operation when thread have to be cut & feed rod is used to transmit the power from
lathe spindle to apron gears via large number of gears.

 Apron mechanism: Apron mechanism used for transforming rotary motion of the feed
rod and the lead screw into the feed motion of the carriage
 Thread Cutting Mechanism:

 Thread Cutting Mechanism is used to produce screw thread along the work

piece.

 The rotation of the lead screw is used to transverse the tool along the work

piece to produce screw thread.

 It uses half-nut mechanism which makes the carriage to engage or disengage

with the lead screw.

 ACCESSORIES AND ATTACHMENTS OF LATHE:

 The important lathe accessories include centers, catch plates and

carriers, chucks, collets, face plates, angle plates, mandrels, and
rests.
 They are used either for holding and supporting the work or for
holding the tool.
 Attachment are additional equipment used for specific purposes.
They include stops, thread chasing dials turning, milling,
grinding , gear cutting , turret, cutter attachment.
 Lathe centers : The most common method of holding the job in a lathe is between
the two centers generally known as live centre (head stock centre) and dead centre
(tailstock centre).

 Carriers or driving dog and catch plates: These are used to drive a work piece
when it is held between two centers. Carriers or driving dogs are attached to the
end of the job by a setscrew & Catch plates are either screwed or bolted to the
nose of the headstock spindle. This imparts a positive drive between the lathe
spindle and job.
 Chucks: Chuck is one of the most important devices for holding and rotating a
job in a lathe. It is basically attached to the headstock spindle of the lathe.
There are a number of types of lathe chucks:
 Three jaws or universal
 Four jaw independent chuck
 Magnetic chuck
 Collet chuck
 Air or hydraulic chuck operated chuck
 Combination chuck
 Drill chuck
 Face plates: Face plates are employed for holding jobs, which cannot be
conveniently held between centers or by chucks. A face plate possesses the
radial, plain and T slots for holding jobs or work-pieces by bolts and clamps.
 Angle plates: Angle plate is a cast iron plate. Holes and slots are provided
on both faces so that it may be clamped on a faceplate and can hold the
job or work piece on the other face by bolts and clamps.
 Mandrels: A mandrel is a device used for holding and rotating a hollow job
that has been previously drilled or bored. It is generally used in order to
machine the entire length of a hollow job.
 Rests: A rest is a lathe device, which supports a long slender job, when it is turned
between centers or by a chuck. The two types of rests commonly used for supporting
a long job in an engine lathe are the steady or centre rest and the follower rest.

Fig: Steady rest

Fig: Follower rest
 SPECIFICATION OF LATHE:

 The size of a lathe is generally specified by the following means:

 Swing or maximum diameter that can be rotated over the bed ways
 Maximum length of the job that can be held between head stock and tail stock
Centres
 Bed length, which may include head stock length also
 Maximum diameter of the bar that can pass through spindle or collect chuck of
Capstan lathe.
 LATHE OPERATIONS:

 The various operations have been performed on the lathe machine

to generate the desired shape.
1. Turning 8. Threading
2. Facing 9. Taper Turning
3. Knurling
4. Parting
5. Drilling
6. Boring
7. Reaming
 Turning

 Turning is the most commonly used operation in a lathe. It remove

excess material from the work piece to produce a cone shaped or

cylindrical surface. Following are the type of turning operation.

 Straight turning
 Rough turning
 Finish turning
 Shoulder turning
 Taper turning
 Facing

 Facing is an operation of machining the end of work piece for

generating flat surfaces. The feed, in this case, is given in a
direction perpendicular to the axis of revolution.
 This is also used to cut the work to the required length.
 Knurling

 Knurling is the process of embossing a diamond shape pattern on the

surface of a work piece.
 The purpose of knurling is to provide an effective gripping surface on
work piece to prevent it from slipping when operated by hand.
 Parting

 Parting and grooving are similar operations. In this, a flat ‐ nosed

tool would plunger cut the work piece with a feed in the direction
perpendicular to the axis of revolution.
 This operation is generally carried out for cutting off the part from
the parent material.
 Drilling

 Drilling is the operation of making cylindrical holes into the work

piece by the rotating cutting edge of a cutter known as drill.
 A twist Drill is held in the tailstock, and is fed into the rotating
work piece by feeding the tailstock.
 Boring

 Boring is the operation of enlarging a hole already made by a

single point boring tool called as boring bar.
 Reaming

 Reaming is the operation of finishing and sizing a hole which has

been previously drilled or bored.
 The tool used is called the reamer ,which has multiple cutting
edges.
 Threading

 Thread cutting is operation of producing a helical groove on

spindle shape such as V, square or power threads on a cylindrical
surface.
 The cutting tool must travel a distance equal to the pitch (in mm)
as the work piece completes a revolution.
 Taper and Taper Turning

 A taper is defined as a uniform increase or decrease in diameter of

a piece of work measured along its length.
 Taper turning means to produce a conical surface by gradual
reduction in diameter from a cylindrical job.
 A taper can be turned by anyone of the following methods:

1. By swivelling the compound rest

2. By setting over the tailstock centre
3. By a broad nose form tool
4. By a taper turning attachment
5. By combining longitudinal and cross feed in a special lathe
 Taper Turning by Swivelling the Compound Rest

 This method uses the principle of turning taper by rotating the work
piece on the lathe axis and feeding the tool at an angle to the axis of
rotation of the work piece.
 This method is limited to turn a short taper.
 DRILLING MACHINE
• Drilling is an operation of making a circular hole by
removing a volume of metal from the job by cutting
tool called drill. A drill is a rotary end-cutting tool with
one or more cutting lips and usually one or more
flutes for the passage of chips and the admission of
cutting fluid. A drilling machine is a machine tool
designed for drilling holes in metals. It is one of the
most important and versatile machine tools in a
workshop. Besides drilling round holes, many other
operations can also be performed on the drilling
machine such as counter- boring, countersinking,
honing, reaming, lapping, sanding etc.
 DRILLING MACHINE CLASSIFICATION
1. Portable drilling machine
2. Sensitive drilling machine
– a) Bench mounting
– b) Floor mounting
3. Upright drilling machine
– a) Round column section
– b) Box column section machine

4. Radial drilling machine

a) Plain
b) Semi universal
c) Universal
5. Gang drilling machine
6. Multiple spindle drilling machine
7. Automatic drilling machine
8. Deep hole drilling machine
 Radial Drilling Machine
• The radial drilling machine consists of a heavy, round vertical
column supporting a horizontal arm that carries the drill head.
• Arm can be raised or lowered on the column and can also be
swung around to any position over the work and can be locked
in any position.
• The drill head containing mechanism for rotating and feeding
the drill is mounted on a radial arm and can be moved
horizontally on the guide-ways and clamped at any desired
position.
• The table of radial drilling machine may also be rotated through
360 deg.
• The radial drilling machine is used primarily for drilling medium
to large and heavy workpieces.
 Following are the different part of the radial drilling machine.
• BASE: The base of the radial drilling is a large rectangular casting that is finish
on the top to supports a column on its one end and to hold the work table at
the other end. In some machine T-slot are provided on the base for clamping
work when it serves as a table.
• COLUMN: It is cylindrical casting that is mounted vertically at one end of
base. It supports the radial arm which may slide up or down on its face. An
electric motor mounted on top of the column which imparts vertical
adjustment of the arm by rotating a screw passing through a nut attached to
the arm.
• RADIAL ARM: It is mounted on column extends horizontally over the base. It
is massive casting with its front vertical face accurately machine to provide
guide ways on which drill head may be made to slide.
• DRILL HEAD: The drill head is mounted on the radial arm and drives the drill
spindle. It encloses all the mechanism for driving the drill at multiple speed
and at different feed.
• SPINDLE SPEED AND FEED MECHANISM: There are two common method of
driving the spindle. A constant speed motor is mounted at the extreme end
of the radial arm which balances partially the weight of overhanging arm.
 OPERATIONS PERFORMED ON DRILLING MACHINE

1. Drilling 2. Reaming
3. Boring 4. Counter boring
5. Countersinking 6. Spot facing
7. Tapping 8. Lapping
9. Grinding 10. Trepanning.
• Drilling: This is the operation of making a circular
hole by removing a volume of metal from the job by
a rotating cutting tool called drill as shown in Fig.
Drilling removes solid metal from the job to produce
a circular hole.
• Reaming: This is the operation of sizing and finishing
a hole already made by a drill. Reaming is performed
by means of a cutting tool called reamer as shown in
Fig. Reaming operation serves to make the hole
smooth, straight and accurate in diameter. Reaming
operation is performed by means of a multitooth tool
called reamer.
• Boring: Fig. shows the boring operation where
enlarging a hole by means of adjustable
cutting tools with only one cutting edge is
accomplished. A boring tool is employed for
this purpose.
• Counter-Boring: Counter boring operation is
shown in Fig. It is the operation of enlarging
the end of a hole cylindrically, as for the recess
for a counter-sunk rivet. The tool used is
known as counter-bore.
• Counter-Sinking: Counter-sinking operation is shown
in Fig. This is the operation of making a cone shaped
enlargement of the end of a hole, as for the recess
for a flat head screw. This is done for providing a seat
for counter sunk heads of the screws so that the
latter may flush with the main surface of the work.
• Tapping: It is the operation of cutting internal
threads by using a tool called a tap. A tap is similar to
a bolt with accurate threads cut on it. To perform the
tapping operation, a tap is screwed into the hole by
hand or by machine. The tap removes metal and cuts
internal threads, which will fit into external threads
of the same size.
• Lapping: This is the operation of sizing and finishing a
hole by removing very small amounts of material by
means of an abrasive. The abrasive material is kept in
contact with the sides of a hole that is to be lapped, by
the use of a lapping tool.

• Spot-Facing: This is the operation of removing enough

material to provide a flat surface around a hole to
accommodate the head of a bolt or a nut. A spot-
facing tool is very nearly similar to the counter-bore.
 Difference between counter-boring and
countersinking Operations.

Counter‐boring Counter‐sinking
This operation is used for enlarging This operation is used for enlarging the end
only limited portion of the hole. of the hole to give it a cone shape for a
short distance.
The tool is used for counter‐boring is The tool is used for counter‐sinking
Called as counter‐bore. is called as counter‐sink.
The enlarged hole forms a square The enlarged hole form cone shape
Shoulder with a original hole. With original hole.
This is necessary in some cases to This is necessary in some cases to provide
accommodate the heads of bolts, a seat for the counter‐sunk Heads of the
studs and pins. screws.
 Material removal rate (MRR) in drilling:
• The material removal rate (MRR) in drilling is the volume of
material removed by the drill per unit time. For a drill with a
diameter D, the cross-sectional area of the drilled hole is
• Π D2 /4. The velocity of the drill perpendicular to the
workpiece f is the product of the feed fr and the rotational
speed N where N = V /π D.
Thus,
MRR = (Πd2 / 4) (f) mm3 /min
Conversion of feed rate fr (mm/rev) to feed rate
f (mm/min)
f = N fr (mm/min)